Carpet with improved coverage



2 Sheets-Sheet 1 F. W. E. HOESELBARTH CARPET WITH IMPROVED COVERAGE 7n M$1 6 y 3%} 2 V w a a by w J. .mw

Jan. 6, 1959 Original Filed Aug. 13, 1956 INVENTOR.

FRANK M 5 #0532154)?! ATTORNEYS,

29 fie 22 M Z? 5A5 Jan. 6, 1959 F. w. E. HOESELBARTH 2,867,245

CARPET WITH IMPROVED COVERAGE Original Filed Aug. 13, 1956 2Sheets-Sheet 2 E mmvron.

A TTQPA/EYQ United States Patent CARPET WITH IMPRQVED COVERAGE Frank W.E. Hoeselbarth, Carlisle, Pa., assignor to C. H. Masland & Sons,Carlisle, Pa., a corporation of Pennsylvania Originalapplication August13, 1956, Serial No. 603,761. Divided and this application August 27,1957, Serial No. 680,518

2 Claims. (Cl. 139-403) The present invention relates to pile carpets.

This application is a division of my copending application Serial No.603,761, filed August 13, 1956, for Carpet Weaving With ImprovedCoverage.

A purpose of the invention is to obtain improved coverage in pilecarpets having a plurality of warps raised in the pile instaggeredrelation.

A further purpose is to weave a pile carpet having stuifer warp ends ineach dent, one or preferably two opposite binder warp ends in each dent,and selectively one or more pile warp ends in each dent, the pile warpends being raised alternately in the pile, to thread-in a pile warp endof only one set in some of the dents, to thread in a pile warp end ofonly the other set in some of the dents, to thread in a pile ,warp endof both sets in some of the dents and to reverse the lateralrelationship between the stuffer warp ends and the pile Warp ends in thedents having only one pile warp end as compared with those having pileWarp ends of both sets.

A further purpose is to weave a pile carpet, using two sets of pile warpends, binder warp ends, stuifer Warp ends and wefts, by threading in atleast one stufier warp end in each dent, threading in at least onebinder warp end in each dent, threading in in the first, fourth,seventh, etc. dents an end of the first pile warp set on one side of thestutfer warp end and leaving an end out of the second pile warp set,threading in in the second, fifth, eighth, etc. dents an end of thesecond pile warp set on the other side of the stuffer warp end andleaving an end out of the first pile warp set, threading in in thethird, sixth, ninth, etc. dents an end of the first pile warpset on theother side of the stuifer warp end and an end of the second pile warpset on the one side of the stuffer warp end, interweaving the pile warpends of both sets, the stutter warp ends, the binder warp ends andwefts, while raising the pile warp ends of the two sets in the pilepreferably over wires alternately in pile projections at different Weftpositions.

A further purpose is to produce a pile carpet having courses defined byrecurring binder warp ends woven in the same direction, comprising twosets of pile warp ends alternately raised in the pile, at least onestutter warp end in each course, top and bottom wefts above and belowthe stuifer warp ends and certainof the wefts tying in the pile warpends, and at least one binder warp end woven in the same direction ineach course and tying together the top and bottom wefts, the first,fourth, seventh, etc.

courses having an end of the first pile warp set on one.

side of the stufier warp end and having an end out'of the second pilewarp set, the second, fifth, eighth, etc. courses having an end of thesecond pile warp set on the other side of the stutter warp end andhaving an end out of the first pile warp set, and the third, sixth,ninth, etc. courses having an end of the first pile warp set on theother side of the stuffer warp end and having an end of the second pilewarp set on the one side of the stutter warp end.

7 2,867,245 Pat nted Jen- 59 thread-in diagram for weaving accordingtothe invention.

Figure 2 is a conventional warpwise weave diagram showing the stufferwarp ends, binder warp ends, pile warp ends and wefts of a dent havingtwo pile warp ends;

and also showing the stutter warp ends, binder .warp ends,

pile warp ends and wefts of a dent having one pile warp end, with thepile warp end'inthe next dent having only one pile warp end. 7 j

Figure 3 is a photograph of the faceof a pile carpet Woven in accordancewith the invention.

Figure 4 is a diagram of the tops of adjoining loops of pile warp endsin the face of a carpet formed without using the principles of theinvention.

Figure 5 is a view similar to Figure 4 showing the use of the principlesof the present invention.

Describing in illustration but not in limitation and referring to thedrawings: I In the prior art, in accordance with my previous patentsselective thread-ins have been used, employing different lateraldensities of pile warp ends in different dents or courses. v

I have endeavored to utilize this principle to produce novel effects inpile carpets, especially in thevelvet or tapestry weave, utilizing anend in of pile warp A in one dent, an end in of pile warp B in the nextdent, andan end in of pile warp A and an end in of pile warp B in thenext dent. Unless very high pile or very full pile yarns are used,difficulty has been encountered in obtaining adequate coverage. Acrowding etfectoccu'rs, and grinning through the face of the fabric toexpose the back is likely to be exhibited. This constitutes-a limitationon the otherwise desirable staggered weaving according to a. thread-inas above describe I 1 I have discovered that this diificulty. can beovercome, andgreatly improved coverage can be obtainedwith eliminationof the crowding effect, even in relatively lowpile carpets and incarpets using relatively compact pile yarns, if the lateral relation ofthe pile ends to the stufr'er warp ends .in the dents or courses isreversed in the dents having only one pile warp end as comparedto thedents having pile warp ends of both sets. Since the pile warp ends ofthe difiier'ent sets are raised in the pile over wires or as terry loopsor otherwise alternately, the loops or pile projections tend tolaterally engage and displace one another above the back' at crossingpoints, and unless the reversal takes place as above described very poorcoverage is obtained, but-with the reversal the coverage is excellent.

Considering the weave illustrated in Figure 1, I show a reed 20 havingsplits 21 which divide the draw up into dents 22, 23, 24, 25, 26, 27, 28and 30, which are simply intended to be representative dents in thefabric starting at any desired point. There also is a pile warp heddle31 having eyes 32 through which are threaded pile warp ends 33, and apile warp heddle 34 having eyes 35 through which are threaded pile Warpends 36. (See also Figure 2.)

Each one of the dents as shown has a stuffer warp end 37 manipulated bya separate heddle, or if preferred manipulated by long slots on theheddles 31 'and 34 in accordance with the principles of my U. S. Patents2,709,458 and 2,709,460, both granted May 31, 1955;

and 2,713,355 and 2,713,356, both granted July 19, 1955. Eachof thedents also has arbinder warp end 38 manip-z 3 ulat ed by a binder warpheddle (not shown) and a binder Warp end 40 manipulated by anotherbinder warp heddle (not shown). While the particular weave hereillustrated utilizes two binder warp ends Woven in opposition, it willbe understood that it is immaterial, from the standpoint of the presentinvention, whether two binder warp sets are, used or asingle binder warpset is woven in oppositidri to the stuffer warp, as well known.

/ Unlike the usual type of thread-inwhich is the same in" each dent orcourse, in the fabric of the present invention the thread-in. variessequentially. Thus in some dents, in this case dents 22, 25, and 28,etc., the pile warp ends 36 threaded through the eyes 35 of pile warpheddle 34.1ie on the right of the stuifer warp end, or the side towardthe binder warp ends 38 and 40.

[*In some other dents, in this case dents 23, 26 and 30, etc., the pilewarp ends 33 of the otherset are threaded through eyes 32 of the pilewarp heddle 31 on the left of the stuffer warp. In both of the sets ofdents above referred to, where there are ends 36 of one pile warp raisedto the mid-position, forming an upper shed, and all other ends arelowered, forming a lower shed. Wire 42 which may be of any suitablecharacter, cutting, noncutting, high, low, wavy, straight, flag orotherwise, is

inserted in the upper shed, and a shot of upper weft 41 is inserted inthe lower shed.

In the next step corresponding to the positions of lower weft 43, binderwarp ends 38 are lowered and all other ends are raised half ;way,forminga lower shed, and a shot of lower weft 43 is inserted in the lower shed.

At the next position corresponding to the position of upper weft 41, adouble shed is formed. Pile warp ends 36 are fully raised and binderwarp' ends 38 are raised half way, forming an upper shed, and all otherends are lowered, forming a lower shed. The wire 42 is inserted in theupper shed and a shot of weft 41' is inserted in the lower shed. Thiswire may be of any suitable character, as in the case of wire 42.

set there are no ends of the other, pile warp set, and where there areends 33 of the other pile warp set there A aie no ends of the one pilewarp set.

on the other hand, in other dents or courses, ends of both pile warpsets are present. Thus in dents 24, 27 etc., there are ends 36 of onepile warp set and ends 33 of the other pile warp set. Here, however, animportant departure has been made. Whereas in the dents having 1 onlyends 36 of one pile warp set, the pile warp ends lie to the right of thestufier warp end or adjoining the binder warp ends, and in the dentshaving only ends 3 33 of the other pile warp set the pile warp ends lieto the left of the stutter warp end or remote from the binder warp ends,the relationship of the oppositely woven pile warp ends in the dentshaving ends of both pile warps is reversed. Thus in dents 24 and 27 pilewarp end 36 is" on the left of the stutter warp end or remote from thebinder warp ends and carried through a different eye of pile warp heddle34. Likewise pile warp end 33 is reversed and now lies on the right ofthe stulfer warp end or on the side adjoining the binder warp ends andis threaded through a different eye of the pile warp heddle 31. This issuggested by the dot-and-dash eyes and arrows in Figure 1.

. While of course this principle of combining dents havonly an end ofpile warp A placed, say, on the right of the stulferwarp end, and dentshaving only an end of pile Warp B placed, say, on the left of thestuffer warp end, with dents having an end of pile warp A placed,

say, on the left of the stufier warp end and an end of pile warp Bplaced, say, won the right of the stuffer warp end may be variedto'produce different sequences or locations to suit the requirements ofthe designer, it will be evident that best results will be obtained byhaving periodic lateral repeats which may consist of the following:

I (1) A dent or course having only an end of pile warp A to the right ofthe stuifer warp end;

I (2) A dent or course having only an end of pile warp B to the left ofthe stutter warp end;

. (3 A dent or course having an end of pile warp A to the left of thestufEer warp end and an end of pile warp B to the right of the stutferwarp end.

. If these are repeated laterally, the dents mentioned in paragraph (1)will be the first, fourth, seventh, etc. dents,

repeating this series across the fabric; the. dents mentioned inparagraph (2) will be the second, fifth and eighth, etc.dents,.repeating this series across the fabric, and the dents mentionedin paragraph (3) above will be the third, sixth, ninth, etc. dents,repeating this series across the fabric. t In weaving the carpet asshown in Figure 2, the principles of weaving with staggered pile warpsets will be followed. Thus at the position of insertion of upper weft41 a double shed is formed. Pile warp ends 33 are raised to the upperposition, and binder warp ends are While I have illustrated raising ofthe staggered pile warp sets over wires to form pile projections 44, itwill be evident that it is immaterial from the standpoint of the presentinvention whether such pile projections are formed by raising over wiresor by terry weaving or otherw1se.

Figure 3 illustrates the face of a pile carpet corresponding to Figures1 and 2 which has been woven embodying the principles of the invention.

It will be evident that though the pile'is a low pile, very goodcoverage is obtained due'to the reversal effect in the lateral thread-inand any tendency to crowding effect by the nonuniform densitydistribution of pile warp ends is largely overcome.

It will be evident that if the reversal of the position of ends 36 and33 were not accomplished in dents 24, 27 etc., you would have pile warpends 33 and 33 in adjoining relationship, tending to produceconcentrated and poorly distributed pile. On the other hand, as shown inFigure 5, with the reversal of draw-up, in dents 24, 27 etc., there isan alternate distribution or a staggered distributionof pile projectionsspread out over the face of the fabric, so that the order of appearanceis pile warp end 33, pile warp end 36, pile warp end 33 and pile warpend 36. I

Accordingly a very unusual uniformity of distribution is obtainednotwithstanding the nonuniformity of the thread-in.

In view of my invention and disclosure, variations and modifications tomeet individual whim or particular need will doubtless become evident toothers skilled in the art to obtain all or part of the benefits of myinvention without copying the fabric shown, and I, therefore, claim allsuch insofar as they wall within the reasonable spirit and scope of myclaims.

Having thus described my invention what I claim as new and desire tosecure by Letters Patent is:

l. A pile carpet, having courses defined by recurring binder warp endswoven in the same direction compris ing two sets of pile warp endsalternately raised in the pile, at least one stuifer Warp end in eachcourse, top and bottom wefts above and below the stuffer warp ends, andtying in the pile warp ends, and at least one binder warp end woven inthe same direction in each course and tying together the top and bottomwefts, the first, fourth, seventh, etc., courses having an end of thefirst pilevwarp set one one side of the stuifer warp end and having anend out of the second pile warp set, the second, fifth, eighth, etc.,courses having an end of the second pile warp set on the other sideofthe stuffer warp end and having an end out of the first pile warp set,and the third,

sixth, ninth, etc., courses having an end of the first pile Warp set onthe said other side of the stulfer warp end and having an end of thesecond pile warp set on the said one side of the stufier warp end.

2. A pile carpet having courses defined by recurring binder warp endswoven in the same direction, comprising two sets of pile warp endsalternately raised in the pile, at least one stuflEer Warp end in eachcourse, top and bottom wefts above and below the stufier warp ends andtyping in the pile warp ends, and at least one binder warp end woven inthe same direction in each course and typing together the top and bottomwefts, some (type A) of the courses having an end of the first pile warpset and an end out of the second pile warp set, some (type VB) of thecourses having an end of the second pile warp set and an end out of thefirst pile warp set, and some (type C) of the courses having an end ofthe first pile warp set and an end of the second pile warp set, in acourse of the type C the end of the first pile warp set always being onthe one side of the stuffer warp end and the end of the second pile warpset always being on the other side of the stuffer warp end, in a courseof type A the end of the first pile warp set always being on the otherside of the stuifer warp end, and in a course of type B the end of thesecond pile warp set always being on the one side of the stulfer warpend.

No references cited.

